Adjustable steel cage automatic seam welding device and method

Abstract

This invention belongs to the technical field of rebar cage welding, specifically relating to an adjustable automatic rebar cage welding device and method, comprising: a rebar cage lifting mechanism, arranged in a long strip of rebar cage lifting track and installed on the ground; a first main bar fixing mechanism, mounted on the slide groove via a drive wheel at the bottom, including a housing, a moving coil for driving the main bar to rotate, a transmission mechanism for controlling the rotation of the moving coil, and a first electromagnet; an automatic resistance welding mechanism, installed on the ground near the rebar cage lifting track; a second main bar fixing mechanism, a device with the same internal structure as the first main bar fixing mechanism; and a stirrup wire feeding mechanism, installed on the ground near the rebar cage lifting track, for feeding stirrup wire. This adjustable automatic rebar cage welding device solves the problems of inconvenient transportation, difficulty in customizing the rebar cage diameter and the number of main bars, and the inability to automate welding production with existing rebar cage welding equipment.

Description

Technical Field

[0001] This invention relates to the technical field of steel cage welding, and more particularly to an adjustable automatic steel cage welding device and an adjustable automatic steel cage welding method. Background Technology

[0002] With the acceleration of urbanization and the continuous increase in construction projects and urban renovation projects, the requirements for automation and customization of rebar cages are gradually increasing. Existing rebar cage welding machines use PLC control systems to set parameters and drive the coordinated movement of a fixed rotating disc and a moving rotating disc. After the main reinforcement is fixed, the winding reinforcement is wound in a spiral trajectory, and the welding robot simultaneously heats and welds the intersections, realizing the automated synchronous forming of the main reinforcement and the winding reinforcement.

[0003] While existing rebar cage welding machines have played a significant role in automating rebar cage manufacturing, they also present some technical challenges. Regarding reinforcement configuration, a single machine typically can only accommodate one or a few specific combinations of main reinforcement and stirrups. For complex reinforcement requirements, such as combinations with different spacings and arrangements, the equipment may not be able to adjust flexibly, making it difficult to meet diverse engineering needs. Existing rebar cage welding machines consist of several core components, including a drive rail, control console, main reinforcement material rack, and hydraulic support device. Their large size and weight make transportation and installation extremely difficult. Finding a suitable location for installation and debugging within the limited space of a construction site is challenging, necessitating factory production and incurring transportation costs and losses.

[0004] With technological advancements, the market demand for rebar cage welding equipment that can be produced on-site and simultaneously meet both automation and customization requirements is becoming increasingly urgent. This equipment should not only be easy to transport, install, and maintain, but also ensure automated welding and meet the needs of customized rebar cages with various main reinforcement bars and diameters. Therefore, developing a rebar cage welding equipment that is easy to transport, allows for free customization of rebar cage diameter and the number of main reinforcement bars, and enables automated production is a necessary path for technological development. Summary of the Invention

[0005] Based on the shortcomings of the existing technology, the technical problem to be solved by the present invention is to provide an adjustable automatic rebar cage welding device to solve the problems of inconvenient transportation, difficulty in customizing the diameter and number of main bars of the rebar cage, and inability to automate welding production of existing rebar cage welding equipment. The device uses a first main bar fixing mechanism and a second main bar fixing mechanism to clamp and move the rebar on the rebar cage lifting track. In conjunction with the rebar cage lifting mechanism to lift the rebar cage, and the stirrup wire feeding mechanism and the automatic resistance welding mechanism to automatically weld the main bars and stirrups, the automatic rolling welding of the rebar cage is realized.

[0006] Another objective of this invention is to provide an adjustable automatic roll welding method for steel cages, which can be directly applied to existing steel cage production. By numbering the adjustable clamps, and then calling the corresponding numbered clamps, steel cages of different diameters can be produced.

[0007] To achieve the above objectives, the present invention employs the following technical measures:

[0008] The adjustable automatic rebar cage welding device of the present invention includes: a rebar cage lifting mechanism, wherein a long strip of rebar cage lifting track is installed on the ground, including flanges for connecting each rebar cage lifting mechanism, a scissor-type telescopic mechanism for lifting the rebar cage, and a slide groove for providing tracks for a first main bar fixing mechanism and a second main bar fixing mechanism; a first main bar fixing mechanism, which is installed on the slide groove via a drive wheel at the bottom, including a housing, a moving coil for driving the main bar to rotate, a transmission mechanism for controlling the rotation of the moving coil, and a first electromagnet; and an automatic resistance welding mechanism installed on the rebar cage. On the ground near the cage lifting track, there are a resistance welding machine for providing a potential difference, an electric push rod for controlling the electrode position, and a spring for providing welding pressure; a second main reinforcement fixing mechanism, which has the same internal structure as the first main reinforcement fixing mechanism, is mounted on the slide groove via a drive wheel at the bottom, and works with the first main reinforcement fixing mechanism to allow both ends of the main reinforcement to be fixed simultaneously, ensuring the stability of the main reinforcement during roll welding; a stirrup wire feeding mechanism, mounted on the ground near the steel cage lifting track, is used for feeding stirrup wire, and includes a guide tube for limiting and guiding the stirrup.

[0009] Preferably, the moving coil includes a moving coil body, an adjustable gripper for clamping the main rib, a pulley and a circular groove for controlling the relative position between the moving coil body and the adjustable gripper; the adjustable gripper is connected to the pulley via a bearing, and the outer ring of the moving coil body is provided with an outer ring tooth, which meshes with a positioning gear and a transmission gear.

[0010] Furthermore, the transmission mechanism includes a transmission gear and positioning gears. One transmission gear is located at the lower right corner of the housing and is connected to the housing via a bearing. Three positioning gears are located at the lower left, upper left, and upper right corners of the housing and are connected to the housing via bearings.

[0011] Furthermore, the housing is connected to the angle iron bracket by screws, the drive wheel is connected to the angle iron bracket by welding, a distance sensor is fixed to the housing by screws, the housing is connected to the phase sensor by a bearing, and the phase sensor is installed near the outer ring teeth of the moving coil body.

[0012] Furthermore, the adjustable gripper includes an iron block connected to the pulley via a bearing, a linear module connected to the iron block via welding, and a slider connected to the linear module via a lead screw.

[0013] Furthermore, one end of the slider is fixedly connected to one end of the bottom of the scissor telescopic frame by screws, the top of the scissor telescopic frame forms a sliding pair with the upper sliding groove, and the bottom of the scissor telescopic frame forms a sliding pair with the lower sliding groove; a square cylinder is connected to the top of the upper sliding groove by screws, the middle of the square cylinder is connected to the cylinder pulley through a bearing, and an electromagnet and an air pump are connected to the bottom of the square cylinder by screws.

[0014] Preferably, the flange is fixed to both ends of the large square tube by welding, the two large square tubes are installed on the ground, the two large square tubes are connected together by welding a rectangular base plate, the two guide rails are installed on the inner side of both ends of the large square tube by screws, and the slide groove is embedded in the top of the large square tube.

[0015] Furthermore, the scissor telescopic mechanism is installed on a rectangular base plate inside the two guide rails. The scissor telescopic mechanism and the guide rails form a sliding pair. The top of the scissor telescopic mechanism is fixed with a roller for supporting the reinforcing cage via a bearing. A mounting plate is welded to the middle of the rectangular base plate. A winch motor is mounted on the mounting plate with screws. One side of the bottom of the scissor telescopic mechanism is welded to one end of a wire rope. The other end of the wire rope is fixed to the reel of the winch motor.

[0016] Furthermore, the stirrup feeding mechanism includes a first bracket installed on the ground near the steel cage support track by expansion bolts, a stirrup coil is fitted on the crossbar at the top of the first bracket, a second bracket is welded to the top of the first bracket, and the guide tube is welded to the second bracket.

[0017] Accordingly, the present invention also provides an adjustable automatic rebar cage welding method, using the aforementioned adjustable automatic rebar cage welding device, the steps of which are as follows:

[0018] S1. Rebar Cage Adjustment: This device is used for welding rebar cages with 24 or fewer main bars. Before welding, the state of the moving coil needs to be adjusted. Power is provided by a stepper motor, pulley, belt, and transmission gear to make the moving coil rotate. The rotation of the moving coil is used to represent the above transmission process. The adjustable jaws on the moving coil are numbered. The specific numbering starts from the adjustable jaw at the middle of the rightmost end of the moving coil, and proceeds clockwise from number 1 to number 24. All the adjustable jaws on the entire moving coil are numbered.

[0019] S1-1. Adjust the number of adjustable clamps according to the number of main reinforcement bars required for a single rebar cage. For rebar cages with 3, 4, 6, 8, 12, or 24 main reinforcement bars, directly use the adjustable clamps shown in the table. For rebar cages with other main reinforcement bar numbers, the position of the selected adjustable clamp relative to the moving coil body needs to be adjusted. The adjustment method is as follows: Adjust the adjustable clamp that needs to be adjusted to the position closest to the first electromagnet by rotating the moving coil. Then, release the lock of the pulley relative to the circular groove, energize the first electromagnet to generate a magnetic field, and rotate the moving coil to make the position of the adjustable clamp that needs to be adjusted relative to the moving coil body reach a certain position. This position makes the distance between each pair of adjacent adjustable clamps equal. Finally, lock the position of the pulley relative to the moving coil body. Repeat the above adjustment method until all adjustable clamps reach the specified position.

[0020] S1-2. Adjust the length of the adjustable gripper according to the diameter of the steel cage, start the linear module, which pushes the slider to move, so that the scissor telescopic frame extends or shortens. After the scissor telescopic frame reaches the target length, the linear module stops working and self-locks.

[0021] S1-3. Adjust the relative positions of the first main reinforcement fixing mechanism and the second main reinforcement fixing mechanism on the steel cage lifting track. Drive the drive wheel to rotate by the walking motor, thereby moving the first main reinforcement fixing mechanism on the slide. Adjust the first main reinforcement fixing mechanism to the middle of the steel cage lifting track formed by the steel cage lifting mechanism in this way. The second main reinforcement fixing mechanism is placed close to the first main reinforcement fixing mechanism in the same way, ensuring that the automatic resistance welding mechanism and the stirrup wire feeding mechanism are located between the first main reinforcement fixing mechanism and the second main reinforcement fixing mechanism.

[0022] S1-4. Fixing the main ribs: First, place the main rib on the called adjustable jaw on the second main rib fixing mechanism. Place one end of the main rib between the corresponding cylinder pulleys of the second main rib fixing mechanism. Then, supply air through two air pumps. The cylinder pulleys hold the main rib, and the cylinder pulleys of the second main rib fixing mechanism are locked. After placing one main rib, rotate the moving circle so that the next adjacent called adjustable jaw is directly below the moving circle. Repeat the above steps until all the main ribs are fixed. Move the second main rib fixing mechanism until the other end of the main rib is between the cylinder pulley of the corresponding called adjustable jaw inserted into the first main rib fixing mechanism. Then, fix the other end of all the main ribs in the same way as above.

[0023] S2. Automatic Roll Welding of Reinforcing Cage: Extend the piston head of the electric actuator to a certain position, so that the far end of the contact plate extends outward a certain length after intersecting the circle formed by the main reinforcement bars, and keep the piston head locked. Weld one end of the stirrup to the first main reinforcement bar below the contact plate, while ensuring that the stirrup passes through the groove in the middle of the contact plate. Rotate the moving coils in the first and second main reinforcement bar fixing mechanisms at the same speed, so that the stirrup begins to wrap around the main reinforcement bar. At the same time, the first and second main reinforcement bar fixing mechanisms move at the same speed in the direction from the second main reinforcement bar fixing mechanism to the first main reinforcement bar fixing mechanism. This speed depends on the required stirrup density of the reinforcing cage; the higher the density, the slower the speed. Welding begins. At this time, the first electrode contacts the main reinforcement bar, and the second electrode contacts the stirrup. Control the resistance welding machine to start and provide a potential difference between the first and second electrodes. In this process, the first main... After each rebar cage lifting mechanism passes through a rebar cage, the rebar cage lifting mechanism performs the following operations: the winch motor starts, and the steel wire rope makes the circle formed by the roller and the cylinder pulley of the adjustable gripper tangent, allowing the roller to lift the rebar cage; after the welding of the stirrups reaches the required length, the first and second main rebar fixing mechanisms are stopped moving on the slide, and the moving coils of the first and second main rebar fixing mechanisms stop rotating. The piston head of the electric push rod returns to its original position, the resistance welding machine stops working, the air pump stops supplying air, the cylinder pulley releases its clamp, and the second and first main rebar fixing mechanisms move away from each other. The welded rebar cage is lifted onto the rebar cage lifting mechanism, the welded rebar cage is removed, the winch motor is reversed, and the roller is lowered. At this point, the entire automatic rebar cage rolling welding process ends.

[0024] Based on the above, the beneficial effects of the adjustable automatic rebar cage welding device and method of the present invention are as follows:

[0025] 1. This invention can achieve automated production of steel cages of any specification with up to two meters in length and up to 24 main bars by utilizing the telescopic and clamping parts of the scissor-type telescopic frame.

[0026] 2. The clamping mechanism of this invention is easy to use and simple to load; only a portion of the reinforcing bar needs to be inserted for automatic loading. This saves time spent on feeding and increases work efficiency.

[0027] 3. This invention adopts a modular design, which is convenient for disassembly, assembly, and transportation. It can be directly transported to the construction site and assembled, and can be used immediately after production, effectively avoiding the costs and losses incurred during the transportation of steel cages. Attached Figure Description

[0028] The accompanying drawings, which are provided to further illustrate this application and form part of this application, illustrate exemplary embodiments of this application and are used to explain this application, but do not constitute an undue limitation of this application.

[0029] Figure 1 This is a schematic diagram of the adjustable automatic rebar cage welding device of the present invention.

[0030] Figure 2 This is a schematic diagram of the structure of the first main rib fixing mechanism of the present invention;

[0031] Figure 3 This is a schematic diagram of the automatic resistance welding mechanism of the present invention;

[0032] Figure 4 This is a schematic diagram of the stirrup wire feeding mechanism of the present invention;

[0033] Figure 5 This is a schematic diagram of the steel cage lifting mechanism of the present invention;

[0034] Figure 6 This is a partially enlarged view of the moving coil of the present invention;

[0035] Figure 7 This is a schematic diagram of the adjustable gripper structure of the present invention;

[0036] Figure 8 This is a schematic diagram of the structure of each mechanism of the present invention for transmission, sensing and adjustment;

[0037] Figure 9 This is a schematic diagram of the structure of the adjustable grippers that can be fully called on the moving coil of the present invention.

[0038] Explanation of reference numerals in the attached figures:

[0039] 1000-First Main Reinforcing Bar Fixing Mechanism:

[0040] 1100 - Outer shell; 1200 - Moving coil; 1210 - Adjustable gripper; 1211 - Square cylinder; 1212 - Cylinder pulley; 1213 - Upper slide groove; 1214 - Scissor telescopic frame; 1215 - Lower slide groove; 1216 - Iron block; 1217 - Linear module; 1218 - Slider; 1219 - Electromagnet; 121X - Air pump; 1220 - Pulley; 1230 - Circular slide groove; 1240 - Moving coil body;

[0041] 1300 - Transmission mechanism; 1310 - Transmission gear; 1320 - Positioning gear; 1330 - Belt; 1340 - Pulley; 1350 - Stepper motor;

[0042] 1400 - Walking motor; 1500 - First electromagnet; 1600 - Angle iron bracket; 1700 - Drive wheel; 1800 - Distance sensor; 1900 - Phase sensor;

[0043] 2000-Automatic Resistance Welding Mechanism:

[0044] 2100 - Resistance welding machine; 2200 - Lifting box; 2300 - Electric actuator; 2400 - Spring; 2500 - Contact plate; 2501 - First electrode; 2502 - Second electrode; 2600 - Brush;

[0045] 3000 - Second main reinforcement fixing mechanism;

[0046] 4000-Stirrup Wire Feeding Mechanism:

[0047] 4100 - First support; 4200 - Stirrup coil; 4300 - Second support; 4400 - Guide tube;

[0048] 5000-Reinforcing Cage Lifting Mechanism:

[0049] 5100 - Large square tube; 5200 - Flange; 5300 - Guide rail; 5400 - Scissor telescopic mechanism; 5500 - Slide rail; 5600 - Mounting plate; 5700 - Winch motor; 5800 - Wire rope; 5900 - Drum. Detailed Implementation

[0050] Below, in conjunction with Figures 1 to 9 This invention provides a detailed description of an adjustable automatic rebar cage welding device and method.

[0051] This invention provides an adjustable automatic rebar cage welding device, such as... Figure 1 As shown, the system includes a first main bar fixing mechanism 1000 and a second main bar fixing mechanism 3000 for fixing the main bars, an automatic resistance welding mechanism 2000 for welding stirrups, a stirrup wire feeding mechanism 4000 for feeding stirrup wire, and a steel cage lifting mechanism 5000 for preventing the steel cage from bending. Several steel cage lifting mechanisms 5000 are installed on the ground and are connected by flanges 5200 to form a long strip steel cage lifting track. Automatic resistance welding mechanism 2000 and stirrup wire feeding mechanism 4000 are installed on the ground on both sides of the steel cage lifting track. The first main bar fixing mechanism 1000 and the second main bar fixing mechanism 3000 are installed on the slide groove 5500 of the steel cage lifting mechanism 5000 through their respective drive wheels 1700.

[0052] Depend on Figure 2 , Figure 6 , Figure 8As shown, the first main reinforcement fixing mechanism 1000 includes a housing 1100, a moving coil 1200 for driving the main reinforcement to rotate, a transmission mechanism 1300 for controlling the rotation of the moving coil 1200, a walking motor 1400 for controlling the movement of the first main reinforcement fixing mechanism 1000 on the rebar cage lifting mechanism 5000, a first electromagnet 1500 for controlling the relative position of the adjustable gripper 1210 and the moving coil body 1240, an angle iron bracket 1600 for maintaining the stability of the housing 1100, a drive wheel 1700 for driving the housing 1100 to move on the slide groove 5500, a distance sensor 1800 for monitoring the distance the first main reinforcement fixing mechanism 1000 moves on the rebar cage lifting mechanism 5000, and a phase sensor 1900 for monitoring the rotation angle and rotation speed of the moving coil 1200. The drive wheel 1700 is engaged in the slide groove 5500 and is welded to the angle iron bracket 1600. The housing 1100 is connected to the angle iron bracket 1600 via... The screws are connected to the angle iron bracket 1600. The transmission mechanism 1300 is connected to the housing 1100 through the bearings. The moving coil 1200 meshes with the positioning gear 1320 and the transmission gear 1310 in the transmission mechanism 1300 through the outer ring teeth of the moving coil body 1240. The walking motor 1400 is connected to the housing 1100 by welding. The first electromagnet 1500 is fixed to the housing 1100 by screws. The distance sensor 1800 is fixed to the housing 1100 by screws. The phase sensor 1900 is connected to the housing 1100 through the bearings. At the same time, the phase sensor 1900 is installed near the outer ring teeth of the moving coil body 1240. The second main rib fixing mechanism 3000 and the first main rib fixing mechanism 1000 are devices with the same internal structure. The purpose of setting the first main rib fixing mechanism 1000 and the second main rib fixing mechanism 3000 is to allow both ends of the main rib to be fixed at the same time, so as to ensure the stability of the main rib during roll welding.

[0053] The moving coil 1200 includes a moving coil body 1240, an adjustable gripper 1210 for clamping the main rib, a pulley 1220, and a circular groove 1230. The pulley 1220 and the circular groove 1230 cooperate with each other. The adjustable gripper 1210 is connected to the pulley 1220 through a bearing. The outer ring of the moving coil body 1240 is provided with an outer ring tooth, which meshes with the positioning gear 1320 and the transmission gear 1310.

[0054] The transmission mechanism 1300 includes a transmission gear 1310, a belt 1330, and a pulley 1340, as well as a stepper motor 1350 and positioning gears 1320. One transmission gear 1310 is located at the lower right corner of the housing 1100 and connected to the housing 1100 via a bearing. Three positioning gears 1320 are located at the lower left, upper left, and upper right corners of the housing 1100 and connected to the housing 1100 via bearings. The belt 1330 is connected to the transmission gear 1310 and the pulley 1340 via friction. The pulley 1340 is connected to the stepper motor 1350 via a pin. The stepper motor 1350 is connected to the housing 1100 via bearings and screws.

[0055] The purpose of this structure is that, during operation, the pulley 1220 self-locks, restricting its sliding within the circular groove 1230. The stepper motor 1350 operates as needed, driving the transmission gear 1310 to rotate via the belt 1330, which in turn drives the moving coil body 1240 to rotate. The positioning gear 1320 engages with the outer ring teeth of the moving coil body 1240, fixing the moving coil 1200 and preventing translation. Due to the self-locking of the pulley 1220, the moving coil body 1240 can drive the pulley 1220 and the adjustable gripper 1210 to rotate. When the main rib is fixed on the adjustable gripper 1210 of the moving coil 1200, the transmission mechanism 1300 drives the moving coil 1200 to rotate, which in turn drives the main rib to rotate. The travel motor 1400 operates as needed, driving the drive wheel 1700 to rotate, which in turn drives the first main rib fixing mechanism 1000 to rotate within the groove 5500. The linear motion; when the number of main ribs needs to be adjusted, the adjustable gripper 1210 that needs to be adjusted is adjusted to the position closest to the first electromagnet 1500 by rotating the moving coil 1200, the pulley 1220 connected to the adjustable gripper 1210 is released relative to the circular groove 1230, the first electromagnet 1500 is started, and the stepper motor 1350 is controlled to rotate in the direction that needs to be adjusted, thereby driving the rotating coil body 1240 to rotate. During this process, the adjustable gripper 1210 remains stationary due to the traction of the first electromagnet 1500, realizing the controllable relative motion between the adjustable gripper 1210 and the moving coil body 1240. When the outer gear ring of the moving coil body 1240 rotates past the probe of the phase sensor 1900, the ferromagnetic gear ring will change the magnetic field distribution and generate a voltage pulse signal. The phase sensor 1900 can record information such as the rotation angle and rotation speed of the moving coil 1200.

[0056] Depend on Figure 7As shown, the adjustable gripper 1210 includes, from top to bottom, a square cylinder 1211, a cylinder pulley 1212, an upper sliding groove 1213, a scissor-type telescopic frame 1214, a lower sliding groove 1215, and an iron block 1216. It also includes an electromagnet 1219 and an air pump 121X connected to the bottom of the square cylinder 1211 by screws, a linear module 1217 connected to the iron block 1216 by welding, and a slider 1218 connected to the linear module 1217 by a lead screw. One end of the slider 1218 is connected to the scissor-type telescopic frame 1214. One end of the bottom is fixedly connected by screws; the bottom of the square cylinder 1211 is connected to the top of the upper slide groove 1213 by screws, and the middle part of the square cylinder 1211 is connected to the cylinder pulley 1212 by bearings; the upper slide groove 1213 and the top of the scissor telescopic frame 1214 form a sliding pair, and the lower slide groove 1215 and the bottom of the scissor telescopic frame 1214 form a sliding pair; the bottom of the lower slide groove 1215 is connected to the top of the iron block 1216 by screws, and the side of the iron block 1216 is connected to the pulley 1220 by bearings.

[0057] The purpose of this structure is that, during the operation of the device, the air pump 121X supplies air to the square cylinder 1211, and the cylinder pulley 1212 in the middle of the square cylinder 1211 is pushed, thereby causing the main reinforcement to be clamped. The cylinder pulley 1212 can slide or lock as needed. When it is necessary to adjust the diameter of the welded steel cage, the linear module 1217 moves in the required direction, and the slider 1218 moves horizontally, thereby driving the scissor telescopic frame 1214 to extend or shorten, thereby changing the diameter of the welded steel cage.

[0058] Depend on Figure 3As shown, the automatic resistance welding mechanism 2000 includes a resistance welding machine 2100, a lifting box 2200, an electric push rod 2300 for controlling electrode position, a spring 2400 for providing welding pressure, a contact plate 2500, and a brush 2600, serving as the first electrode 2501 and the second electrode 2502 for resistance welding. The resistance welding machine 2100 and the lifting box 2200 are installed on the ground near the steel cage lifting track. The electric push rod 2300 is screwed to the top of the lifting box 2200, and the spring 2400 is screwed to the piston head at the end of the electric push rod 2300. The contact plate 2500 is connected to the spring 2400 via a bearing. The first electrode 2501 and the second electrode 2502 are part of the contact plate 2500, and only these two parts of the contact plate 2500 are conductive media, while the rest are not. The insulating medium, brush 2600, is fixed in the contact plate 2500 by insulating pins. The positive and negative poles of the resistance welding machine 2100 are connected to brush 2600, which continuously generates a high potential difference during operation. Brush 2600 is connected to the first electrode 2501 and the second electrode 2502, respectively, providing a potential difference between them. The first electrode 2501 will contact the main rib, and the second electrode 2502 will contact the stirrup. During roll welding, the electric push rod 2300 extends the piston head to a certain position. This position allows the far end of the contact plate 2500 to extend outward by a certain length after intersecting the circle formed by the main rib, while keeping the piston head locked. After the contact plate 2500 contacts the main rib during roll welding, the spring 2400 will be compressed due to the push of the main rib, thereby increasing the contact time and pressure between the contact plate 2500 and the main rib, and increasing the firmness of the resistance weld.

[0059] Depend on Figure 4 As shown, the stirrup feeding mechanism 4000 includes a first support 4100, a stirrup coil 4200, a second support 4300, and a guide tube 4400. The first support 4100 is installed on the ground near the rebar cage support track by expansion bolts. The stirrup coil 4200 is fitted onto the crossbar at the top of the first support 4100. The second support 4300 is connected to the top of the first support 4100 by welding. The guide tube 4400 is connected to the second support 4300 by welding. The purpose of this structure is that during the automatic rolling welding process of the rebar cage, the stirrups in the stirrup coil 4200 will pass through the holes of the guide tube 4400 and wrap around the main reinforcement. After being limited by the guide tube 4400, the stirrups can be wrapped around the main reinforcement more evenly.

[0060] Depend on Figure 5As shown, the rebar cage lifting mechanism 5000 includes a large square tube 5100, flanges 5200 for connecting each rebar cage lifting mechanism 5000, a scissor-type telescopic mechanism 5400 for lifting the rebar cage, guide rails 5300 for limiting the movement of the scissor-type telescopic mechanism 5400, and a winch motor 5700 for controlling the extension and retraction of the scissor-type telescopic mechanism 5400. Two large square tubes 5100 are installed on the ground and welded together by a rectangular base plate. The flanges 5200 are welded to both ends of the large square tubes 5100. Two guide rails 5300 are installed on the inner sides of both ends of the large square tubes 5100 with screws. The scissor-type telescopic mechanism 5400 is mounted on the two guide rails 5300. On the rectangular base plate inside the 00, the scissor telescopic mechanism 5400 and the guide rail 5300 form a moving pair. The top of the large square tube 5100 is inlaid with a slide groove 5500, which serves as the moving track for the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000. The mounting plate 5600 is welded to the middle of the rectangular base plate. The winch motor 5700 is mounted on the mounting plate 5600 with screws. One end of the wire rope 5800 is welded to one side of the bottom of the scissor telescopic mechanism 5400. The other end of the wire rope 5800 is fixed to the reel of the winch motor 5700. The top of the scissor telescopic mechanism 5400 is fixed with a roller 5900 for lifting the steel cage by bearings.

[0061] The purpose of this structure is that, during the operation of the device, the chute 5500 provides a track for the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000, the flange 5200 provides bolt holes so that the reinforcement cage lifting mechanisms 5000 are connected to form a long strip of reinforcement cage lifting track, and the guide rail 5300 provides a track for the extension and retraction of the scissor telescopic mechanism 5400. When the reinforcement cage needs to be lifted, the winch motor 5700 starts, drives the wire rope 5800 to tighten, and then drives the scissor telescopic mechanism 5400 to lift, thus lifting the drum 5900, and the reinforcement cage is lifted by the drum 5900.

[0062] Depend on Figure 9 As shown, the number of adjustable jaws 1210 used is adjusted according to the number of main bars required for a single steel cage. The specific numbering starts from the adjustable jaw 1210 at the rightmost center of the figure, and proceeds clockwise from number 1 to number 24. All the adjustable jaws 1210 on the entire moving coil 1200 are numbered.

[0063] Based on the aforementioned adjustable automatic rebar cage welding device, this invention proposes an adjustable automatic rebar cage welding method, comprising the following steps:

[0064] S1. Rebar Cage Adjustment: This device performs welding operations on rebar cages with 24 or fewer main bars. Before welding, the state of the moving coil 1200 needs to be adjusted. Power is provided by the stepper motor 1350, and the transmission is achieved through the pulley 1340, belt 1330, and transmission gear 1310, causing the moving coil 1200 to rotate. The rotation of the moving coil 1200 directly represents the above transmission process. The adjustable grippers 1210 on the moving coil 1200 are numbered. The specific numbering starts from the adjustable gripper 1210 at the rightmost middle of the moving coil, and proceeds clockwise from number 1 to number 24. All the adjustable grippers 1210 on the moving coil 1200 are numbered.

[0065] S1-1. Adjust the number of adjustable jaws 1210 used according to the number of main reinforcement bars required for a single rebar cage. Specific usage numbers can be found in Table 1. For rebar cages with 3, 4, 6, 8, 12, or 24 main reinforcement bars, directly use the adjustable jaws 1210 shown in the table. For rebar cages with other main reinforcement bar numbers, the position of the used adjustable jaw 1210 relative to the moving coil body 1240 needs to be adjusted. The adjustment method is as follows: adjust the adjustable jaw 1210 that needs adjustment by rotating the moving coil 1200 until it is closest to the first electromagnetic... The position of the first electromagnet 1500 is determined, and then the lock of the pulley 1220 relative to the circular groove 1230 is released. This energizes the first electromagnet 1500 to generate a magnetic field, and the moving coil 1200 is rotated so that the position of a certain adjustable jaw 1210 relative to the moving coil body 1240 is adjusted to a certain position. This position makes the distance between any two adjacent adjustable jaws 1210 equal. Finally, the position of the pulley 1220 relative to the moving coil body 1240 is locked. The above adjustment method is repeated until all adjustable jaws 1210 reach the specified position.

[0066] S1-2. Adjust the length of the adjustable gripper 1210 according to the diameter of the steel cage, start the linear module 1217, which pushes the slider 1218 to move, so that the scissor telescopic frame 1214 extends or shortens. After the scissor telescopic frame 1214 reaches the target length, the linear module 1217 stops working and self-locks.

[0067] S1-3. Adjust the relative positions of the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000 on the steel cage lifting track. Drive the drive wheel 1700 to rotate by the walking motor 1400, thereby moving the first main reinforcement fixing mechanism 1000 on the slide 5500. In this way, adjust the first main reinforcement fixing mechanism 1000 to the middle of the steel cage lifting track composed of the steel cage lifting mechanism 5000. The second main reinforcement fixing mechanism 3000 is placed close to the first main reinforcement fixing mechanism 1000 in the same way, ensuring that the automatic resistance welding mechanism 2000 and the stirrup wire feeding mechanism 4000 are located between the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000.

[0068] S1-4. Fixing the main rib: First, place the main rib on the called adjustable gripper 1210 on the second main rib fixing mechanism 3000, and place one end of the main rib between the corresponding cylinder pulleys 1212 of the second main rib fixing mechanism 3000. Then, supply air through the two air pumps 121X, and the cylinder pulleys 1212 clamp the main rib. The cylinder pulleys 1212 of the second main rib fixing mechanism 3000 are locked. After placing one main rib, rotate the moving circle 1200 so that the next adjacent called adjustable gripper 1210 is directly below the moving circle 1200. Repeat the above steps until all the main ribs are fixed. Move the second main rib fixing mechanism 3000 until the other end of the main rib is between the cylinder pulley 1212 of the called adjustable gripper 1210 inserted into the first main rib fixing mechanism 1000. Then, fix the other end of all the main ribs in the same way as above.

[0069] S2. Automatic Welding of Reinforcing Cage: Extend the piston head of the electric actuator 2300 to a certain position, so that the far end of the contact plate 2500 extends outward by a certain length after intersecting with the circle formed by the main reinforcement, and keep the piston head locked. Weld one end of the stirrup to the first main reinforcement below the contact plate 2500, while ensuring that the stirrup passes through the groove in the middle of the contact plate 2500. Rotate the moving coil 1200 in the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000 at the same speed, so that the stirrup begins to wrap around the main reinforcement, and at the same time, the first main reinforcement is fixed. The fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000 move at the same speed in the direction from the second main reinforcement fixing mechanism 3000 to the first main reinforcement fixing mechanism 1000. This speed depends on the required stirrup density of the reinforcing cage; the higher the density, the slower the speed. Welding begins, at which point the first electrode 2501 contacts the main reinforcement and the second electrode 2502 contacts the stirrup. The resistance welding machine 2100 is started to provide a potential difference between the first electrode 2501 and the second electrode 2502. During this process, the first main reinforcement fixing mechanism 1000 moves along each reinforcing bar. After the cage lifting mechanism 5000 is activated, it will perform the following operations: the hoisting motor 5700 will start, and the steel wire rope 5800 will make the drum 5900 tangent to the circle formed by the cylinder pulley 1212 of the adjustable gripper 1210, allowing the drum 5900 to lift the steel cage; after the welding of the stirrups reaches the required length, the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000 will be stopped from moving on the slide 5500, and the first main reinforcement fixing mechanism 1000 and the second main reinforcement fixing mechanism 3000 will be stopped from moving on the slide 5500. The moving coil 1200 of mechanism 3000 stops rotating, the piston head of electric push rod 2300 returns to its original position, resistance welding machine 2100 stops working, air pump 121X stops supplying air, cylinder pulley 1212 releases clamping, the second main rib fixing mechanism 3000 and the first main rib fixing mechanism 1000 move away from each other respectively, the welded steel cage is lifted on steel cage lifting mechanism 5000, the welded steel cage is taken out, the hoist motor 5700 is controlled to reverse, the drum 5900 is lowered, and the entire automatic steel cage roll welding process ends.

[0070] Table 1: Correspondence between the number of main reinforcing bars and the number of the adjustable clamp 1210.

[0071]

[0072] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any transformations or substitutions that can be understood by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of the present invention.

Claims

1. An adjustable automatic roll-welding device for reinforcing cage, characterized in that, include: The steel cage lifting mechanism (5000) is arranged in a long strip and installed on the ground. It includes a flange (5200) for connecting each steel cage lifting mechanism (5000), a scissor telescopic mechanism (5400) for lifting the steel cage, and a chute (5500) for providing the track for the first main bar fixing mechanism (1000) and the second main bar fixing mechanism (3000). The first main reinforcement fixing mechanism (1000) is mounted on the slide groove (5500) via a drive wheel (1700) at the bottom. It includes a housing (1100), a moving coil (1200) for driving the main reinforcement to rotate, a transmission mechanism (1300) for controlling the rotation of the moving coil (1200), a walking motor (1400) for controlling the movement of the first main reinforcement fixing mechanism (1000) on the steel cage lifting mechanism (5000), and a first electromagnet (1500) for controlling the relative position of the adjustable gripper (1210) and the moving coil body (1240). The walking motor (1400) is welded to the housing (1100), and the first electromagnet (1500) is fixed to the housing (1100) with screws. An automatic resistance welding mechanism (2000) is installed on the ground near the steel cage lifting track. It includes a resistance welding machine (2100), a heightening box (2200), an electric push rod (2300) for controlling the position of the electrodes, a spring (2400) for providing welding pressure, a contact plate (2500), and an electric brush (2600), which serve as the first electrode (2501) and the second electrode (2502) for resistance welding. The electric brush (2600) is connected to the first electrode (2501) and the second electrode (2502) respectively, providing a potential difference between them. The first electrode (2501) will contact the main reinforcement, and the second electrode (2502) will contact the stirrups. The second main rib fixing mechanism (3000) is a device with the same internal structure as the first main rib fixing mechanism (1000). It is installed on the slide groove (5500) through the drive wheel (1700) at the bottom. It works with the first main rib fixing mechanism (1000) to fix both ends of the main rib at the same time, ensuring the stability of the main rib during roll welding. The stirrup feeding mechanism (4000) is installed on the ground near the lifting track of the steel cage and is used for feeding the stirrups, including a guide tube (4400) for limiting and guiding the stirrups. The moving coil (1200) includes a moving coil body (1240), an adjustable clamp (1210) for clamping the main rib, a pulley (1220) and a circular groove (1230) for controlling the relative position between the moving coil body (1240) and the adjustable clamp (1210). The adjustable gripper (1210) is connected to the pulley (1220) via a bearing. The outer ring of the moving ring body (1240) is provided with an outer ring tooth, which meshes with the positioning gear (1320) and the transmission gear (1310). The transmission mechanism (1300) includes a transmission gear (1310), a belt (1330), and a pulley (1340), as well as a stepper motor (1350) and a positioning gear (1320). One transmission gear (1310) is located at the lower right corner of the housing (1100) and connected to the housing (1100) through a bearing. Three positioning gears (1320) are located at the lower left, upper left, and upper right corners of the housing (1100) and connected to the housing (1100) through bearings. The belt (1330) is connected to the transmission gear (1310) and the pulley (1340) through friction. The pulley (1340) is connected to the stepper motor (1350) through a pin. The stepper motor (1350) is connected to the housing (1100) through a bearing and a screw.

2. The adjustable rebar cage automatic roll-welding apparatus of claim 1, wherein, The housing (1100) is connected to the angle iron bracket (1600) by screws, the drive wheel (1700) is connected to the angle iron bracket (1600) by welding, the distance sensor (1800) is fixed to the housing (1100) by screws, the housing (1100) is connected to the phase sensor (1900) by bearings, and the phase sensor (1900) is installed on the outer ring tooth near the moving ring body (1240).

3. The adjustable rebar cage automatic roll-welding apparatus of claim 2, wherein, The adjustable gripper (1210) includes an iron block (1216) connected to the pulley (1220) via a bearing, a linear module (1217) connected to the iron block (1216) via welding, and a slider (1218) connected to the linear module (1217) via a lead screw.

4. The adjustable rebar cage automatic roll-welding apparatus of claim 3, wherein, One end of the slider (1218) is fixedly connected to the bottom end of the scissor telescopic frame (1214) by screws. The top of the scissor telescopic frame (1214) forms a sliding pair with the upper sliding groove (1213), and the bottom of the scissor telescopic frame (1214) forms a sliding pair with the lower sliding groove (1215). The top of the upper slide (1213) is connected to a square cylinder (1211) by screws. The middle part of the square cylinder (1211) is connected to the cylinder pulley (1212) by bearings. The bottom of the square cylinder (1211) is connected to an electromagnet (1219) and an air pump (121X) by screws.

5. The adjustable rebar cage automatic roll-welding apparatus of claim 4, wherein, The flange (5200) is fixed to both ends of the large square tube (5100) by welding. The two large square tubes (5100) are installed on the ground and connected together by a rectangular base plate. The two guide rails (5300) are installed on the inner side of both ends of the large square tube (5100) by screws. The slide groove (5500) is embedded in the top of the large square tube (5100).

6. The adjustable automatic rebar cage welding device according to claim 5, characterized in that, The scissor telescopic mechanism (5400) is installed on the rectangular base plate inside the two guide rails (5300). The scissor telescopic mechanism (5400) and the guide rails (5300) form a sliding pair. The top of the scissor telescopic mechanism (5400) is fixed with a roller (5900) for supporting the steel cage by a bearing. A mounting plate (5600) is welded to the middle of the rectangular base plate. A winch motor (5700) is mounted on the mounting plate (5600) by screws. One side of the bottom of the scissor telescopic mechanism (5400) is welded to one end of a wire rope (5800). The other end of the wire rope (5800) is fixed to the reel of the winch motor (5700).

7. The adjustable automatic rebar cage welding device according to claim 6, characterized in that, The stirrup feeding mechanism (4000) includes a first support (4100) installed on the ground near the steel cage support track by expansion bolts. A stirrup coil (4200) is sleeved on the crossbar at the top of the first support (4100). A second support (4300) is welded to the top of the first support (4100). The guide tube (4400) is connected to the second support (4300) by welding.

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